Endress+Hauser SpectraSensors OXY5500 User manual

Products Solutions Services
Operating Instructions
OXY5500 Gas Analyzer
Sample Conditioning System
BA02196C/66/EN/02.23
70208738

Operating Instructions OXY5500 Gas Analyzer
2 Endress+Hauser
Table of Contents
1About this document ........................... 3
1.1 Warnings..................................................................3
1.2 Symbols on the device.............................................3
1.3 U.S. export compliance............................................3
2Introduction.......................................... 4
2.1 Associated documents ............................................4
2.2 Who should read this manual................................4
2.3 How to use this manual ..........................................4
2.4 General warnings and cautions .............................4
2.5 Manufacturer address.............................................6
3Safety..................................................... 7
3.1 Potential risks affecting personnel........................7
4SCS overview......................................... 8
4.1 About the SCS ..........................................................8
4.2 Typical SCS component overview...........................9
5SCS installation .................................. 11
5.1 Inspecting the SCS ................................................ 11
5.2 Installing the SCS standard enclosure or panel. 11
5.3 Installing the SCS remote panel.......................... 13
5.4 Checking the SCS installation ..............................17
5.5 Starting up the SCS................................................18
5.6 System power up ...................................................19
6Appendix A: Specifications and
drawings ............................................. 20
7Appendix B: Spare parts.................... 31
8Appendix C: Troubleshooting and
maintenance....................................... 32
8.1 Gas leaks ................................................................32
8.2 Contamination.......................................................32
8.3 Excessive sampling gas temperatures and
pressures ................................................................32
8.4 Replacing the membrane separator....................32
8.5 Shutting down the SCS .........................................33
8.6 Troubleshooting ....................................................34
8.7 Service ....................................................................35
8.8 Packing and storage..............................................35
8.9 Storage ...................................................................36
8.10 Disclaimers.............................................................36
8.11 Equipment warranty.............................................36

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1About this document
1.1 Warnings
Structure of Information Meaning
Causes (/consequences)
If necessary, consequences of non-compliance
(if applicable)
‣ Corrective action
This symbol alerts you to a dangerous situation. Failure to avoid the dangerous
situation can result in a fatal or serious injury.
Causes (/consequences)
If necessary, consequences of non-compliance
(if applicable)
‣ Corrective action
This symbol alerts you to a dangerous situation. Failure to avoid this situation
can result in minor or more serious injuries.
Cause/situation
If necessary, consequences of non-compliance
(if applicable)
‣ Action/note
This symbol alerts you to situations which may result in damage to property.
Table 1. Warnings
1.2 Symbols on the device
Symbol Description
The High Voltage symbol that alerts people to the presence of electric potential large enough to cause injury or
damage. In certain industries, high voltage refers to voltage above a certain threshold. Equipment and conductors that
carry high voltage warrant special safety requirements and procedures.
The WEEE symbol indicates that the product should not be discarded as unsorted waste but must be sent to separate
collection facilities for recovery and recycling.
The CE Marking indicates conformity with Essential Health, Safety & Environmental requirements of Directive
2014/34/EU for products sold within the European Economic Area (EEA).
The UKCA marking indicates conformity with Essential Health, Safety & Environmental requirements of Directive
UKSI 2016:1107 for products sold on the market in Great Britain (England, Wales and Scotland).
Table 2. Symbols
1.3 U.S. export compliance
The policy of Endress+Hauser is strict compliance with U.S. export control laws as detailed in the website of the
Bureau of Industry and Security at the U.S. Department of Commerce.

Operating Instructions OXY5500 Gas Analyzer
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2Introduction
Endress+Hauser’s OXY5500 Optical Oxygen Analyzer is a stand-alone device designed to detect oxygen in gases such
as natural gas and air. Its design is based on fluorescence quenching technology that creates very stable, internally
referenced measured values.
2.1 Associated documents
Enclosed in your analyzer system order is the product Safety Instruction for your reference. Please review all
necessary safety instructions before installing or operating your analyzer. This document is an integral part of the
complete document package, which is listed in the following table.
Part Number Document Type Description
BA02195C Operating Instruction Provides a comprehensive overview of the analyzer and step-by-step
installation instructions
BA02196C Sample Conditioning System (SCS)
Operating Instruction
Commission, operation, and maintenance details for the Sample
Conditioning System
SD02868C Service Software Instruction Instructions for operating the OXY5500 Service software to diagnose
and maintain OXY5500 Optical Oxygen Analyzer systems
TI01656C Technical Information Provides technical data on the device with an overview of associated
models available
XA02754C Safety Instruction Safety Instructions for the OXY5500 Optical Oxygen Analyzer
Table 3. Associated documents
For additional instruction manuals, please refer to the following:
•For custom orders: Refer to the Endress+Hauser website (https://endress.com/contact) for the list of local sales
channels to request order-specific documentation. Order-specific documentation is located by analyzer serial
number (SN).
•For standard orders: Refer to the Endress+Hauser website product page to download the published manuals for
the analyzer: www.endress.com.
2.2 Who should read this manual
This manual should be read and referenced by anyone installing, operating, or having direct contact with the
analyzer and SCS.
2.3 How to use this manual
Take a moment to familiarize yourself with this Operating Instruction by reading the "Table of Contents".
There are a number of options and accessories available for the OXY5500 analyzers. This manual has been written to
address the most common options and accessories. Images, tables, and charts have been included to provide a visual
understanding of the analyzer and its functions. Special symbols are also used to provide the user with key
information regarding the system configuration and/or operation. Pay close attention to this information.
2.3.1 Conventions used in this manual
In addition to the symbols and instructional information, this manual is created with “hot links” to enable the user to
quickly navigate between different sections within the manual. These links include table, figure, and section
references and are identified by a pointing finger cursor when rolling over the text. Simply click on the link to
navigate to the associated reference.
2.4 General warnings and cautions
Instructional icons are provided in this manual to alert the user of potential hazards, important information, and
valuable tips. Following are the symbols and associated warning and caution types to observe when servicing the
analyzer

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2.4.1 Safety warning label
The warning label shown below will be affixed to the front side of all analyzer enclosures that contain sample gas.
Figure 1. Safety warning label
Hazards may vary by stream composition. One or more of the following conditions may apply.
Symbol Description
Flammable. Gases used in the processing of this analyzer may be extremely flammable. Any work in a hazardous
area must be carefully controlled to avoid creating any possible ignition sources (e.g., heat, arcing, sparking, etc.).
Toxins. Endress+Hauser analyzers measure a variety of gases, including high-level H2S. Follow all safety protocols
governing toxic gases and potential leaks.
Inhalation. Inhaling toxic gases or fumes may cause physical damage or death.
Table 4. Safety warning symbols
Technicians are expected to follow all safety protocols established by the customer that are necessary for
servicing or operating the analyzer. This may include, but is not limited to, lockout/tag-out procedures, toxic gas
monitoring protocols, personal protective equipment (PPE) requirements, hot work permits, and other
precautions that address safety concerns related to performing service or operation on process equipment
located in hazardous areas.
2.4.2 Equipment labels
Symbol Description
Warning statement for hazardous voltage. Contact may cause electric shock or burn. Turn off and lock out system
before servicing.
Failure to follow all directions may result in damage or malfunction of the analyzer.
PROTECTIVE EARTH GROUND — Symbol indicates the connection point of the ground wire from the main power
source.
Table 5. Equipment labels
2.4.3 Instructional symbols
Symbol Description
General notes and important information concerning the installation and operation of the analyzer.

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Failure to follow all directions may result in fire.
Failure to follow all directions may result in damage or malfunction of the analyzer.
Maximum voltage and current specifications for fuses.
Table 6. Instructional symbols
2.4.4 Special safety symbols used on the equipment
Special safety symbols and labeling are used on the equipment to alert the user to potential hazards and important
information associated with the analyzer. Every symbol and label has significant meaning that should be heeded.
Symbol Description
DO NOT REMOVE — Removal of the seal and/or disassembly of pieces traversed by label voids the warranty.
Table 7. Special symbols
2.5 Manufacturer address
Endress+Hauser
11027 Arrow Route
Rancho Cucamonga, CA 91730
United States
www.endress.com

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3Safety
3.1 Potential risks affecting personnel
This section addresses the appropriate actions to undertake when faced with hazardous situations before or during
service of the analyzer. It is not possible to list all potential hazards within this document. The user is responsible for
identifying and mitigating any potential hazards present when servicing the analyzer.
Technicians are expected to follow all safety protocols established by the customer that are necessary for
servicing the analyzer. These may include, but are not limited to, lockout/tag-out procedures, toxic gas
monitoring protocols, personal protective equipment (PPE) requirements, hot work permits, and other
precautions that address safety concerns related to performing service on process equipment located in
hazardous areas.
3.1.1 Mitigating risks
Refer to the instructions for each situation listed below to mitigate associated risks.
3.1.2 Electrocution hazard
1. Shut off power at the main disconnect external to the analyzer and open the enclosure.
Complete this action before performing any service that requires working near the main input power or
disconnecting any wiring or other electrical components.
2. Open enclosure door.
3.1.3 Explosion hazard
Any work in a hazardous area must be carefully controlled to avoid creating any possible ignition sources (e.g., heat,
arcing, sparking, etc.). All tools must be appropriate for the area and hazards present. Electrical connections must
not be made or broken with power on (to avoid arcing).
3.1.4 Electrostatic discharge
Use a damp cloth to clean the display and keypad to avoid static electricity discharge.
Adhere to all warning labels to prevent damage to the unit. Refer to General warnings and cautions →  for more
information.

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4SCS overview
Personnel should have a thorough understanding of the operation of the OXY5500 analyzer and the SCS, including
procedures presented here, before operating the sample conditioning system.
The process sample at the sample tap may be at a high pressure. A field pressure reducing regulator is located at
the sample tap to reduce pressure and enable operation of the sample conditioning system at a low pressure. Use
extreme caution when operating the sample probe isolation valve and field pressure reducing regulator.
The process sample at the sample tap may be at a high pressure. Make sure that the field pressure reducing
regulator is equipped with an appropriate pressure relief valve.
OXY5500 systems may be ordered with an optional integrated Sample Conditioning System (SCS). Each SCS has been
specifically designed to deliver a sample stream to the analyzer that is representative of the process stream at the
time of sampling. To ensure the integrity of the sample stream and its analysis, care must be taken to install and
operate the SCS properly. Therefore, any personnel intending to operate or service the analyzer and SCS should have
a thorough understanding of the process application and the design of the analyzer and SCS.
Most problems experienced with sample systems tend to result from operating the system differently than intended.
In some cases, the actual process conditions may be different than originally specified (e.g., flow rates, presence of
contaminants, particulates, or condensables that may only exist under upset conditions). By establishing
understanding of the application and the design of the system, most issues can be avoided altogether or easily
diagnosed and corrected ensuring successful normal operation.
If there are any remaining questions concerning the design, operation or maintenance of the SCS, contact Packing
and Storage → .
Process samples may contain hazardous material in potentially flammable and/or toxic concentrations.
Personnel should have a thorough knowledge and understanding of the physical properties and safety
precautions for the sample contents before operating the SCS.
4.1 About the SCS
Refer to the system drawings and schematics in Appendix A for your specific system configuration.
For a typical full-featured SCS, as shown in Figure 2, sample gas enters the sample conditioning unit [at the specified
supply pressure set by an upstream regulator] via the sample supply port, passes through a shut-off valve, pressure
regulator that maintains constant pressure in the measurement manifold, and membrane separator where any liquid
in the stream is removed. Liquid removed by the membrane separator passes through the bypass loop. A continuous
flow (set to the specified level by a metering valve with integrated flow meter) not only flushes the liquid from the
membrane separator but also maintains flow through the sample lines, which reduces sample variation.
Figure 2. Typical OXY5500 with SCS on a panel
The flow exiting the bypass loop is combined with the flow exiting the measurement manifold and sent out the
sample return port to be vented to a safe location.

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4.2 Typical SCS component overview
Some of the typical components used in the SCS will be described in this section. The SCS for your analyzer may not
use all of these components, and may also include additional special devices not discussed here.
For questions regarding your SCS, refer to Service → .
4.2.1 Sample probe
A sample probe is used to provide a representative sample of any process stream. This sample can only be made if
the stream is in a vapor phase. Mixed liquid/vapor streams must be avoided, so the location of the sample probe is
critical in many processes.
Contact Service to provide the temperature, pressure, and complete stream composition of the process stream for
advise and recommendations regarding locating the sample point. Refer to Service → .
A representative sample of the process can only be taken away from the wall of the process piping. Also, dirt and
liquids tend to accumulate close to the walls of the piping, especially near the bottom of horizontal runs of pipe.
Therefore, Endress+Hauser recommends probes that fit well into the pipe. These may be removable to protect the
probe from pipeline “pigging”.
4.2.2 Sample regulators at the probe
The pressure of the sample gas is usually reduced at or very close to the sample probe, sometimes in the probe itself,
to reduce the sample transport lag time to deliver the sample to the analyzer. A guard filter is typically used to
protect the regulator from larger particulates in the sample.
Refer to Figure 3 that shows the interface of the probe and the analyzer system. The analyzer system provided by
Endress+Hauser is represented by the blue dashed outline. The probe and field pressure reducing station may also be
supplied by Endress+Hauser, but is separate from the analyzer system.
Figure 3. Analyzer and probe interface
4.2.3 Sample conditioning system filters
A guard filter is typically installed at the inlet to the SCS with a fine element to protect the flow controllers, flow
meters, and pressure regulators from fine particulates.
A bypass filter with a fritted metal, glass fiber or polymeric membrane filter may also be in place to remove larger
quantities of particulates or entrained liquids and mists. Some filters may fit with liquid knock-out traps to protect
the system from free l/iquids.
Accumulation of liquids in these filters, or a steady flow of liquid from a liquid knock-out trap, should be investigated
and corrected immediately as this is generally an abnormal condition.
4.2.4 Sample regulator heaters
In most applications, the process sample is at high pressure. When the pressure is reduced, the sample cools due to
the Joule-Thompson effect1. The amount of cooling varies greatly depending on the application, but oftentimes must
be offset using a heated sample regulator to prevent condensation of some sample components. Sample probe

Operating Instructions OXY5500 Gas Analyzer
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regulators can be electrically or steam heated. Some probes have the pressure reducing valve parts inserted into the
process piping, so that the Joule-Thompson cooling is offset by warming from the flowing sample. Note that for these
probes to work correctly, the process gas must be flowing anytime the sample is flowing or liquid condensation may
collect in the sample transport line, or even freeze up the sample probe regulator.
1Named for James Prescott Joule and William Thomson, the Joule-Thompson effect describes the increase or decrease
in temperature that accompanies the expansion of gas without production of work or transfer of heat. The cooling
occurs because work must be done to overcome the long-range attraction between the gas molecules as they move
farther apart. (www.britannica.com)
4.2.5 Sample transport tubing
Sample transport tubing must be made of an appropriate material, which may be coated, and of an appropriate
diameter for the application. Many times the sample transport tubing must be heat-traced to prevent sample
condensation or to prevent fluctuations in measurement due to changes in ambient temperature.
4.2.6 Sample bypass flow control
A sample bypass flow control valve and flowmeters are usually provided to maintain a flow of fresh sample to the
SCS even during system shut-down. The flow control valve is typically a needle valve and should be closed very gently
and carefully if used to shut off flow completely to avoid damaging the valve. If the bypass flow meter has a glass
tube, perform an occasional check for evidence of liquid in the tube. If liquid is found in the bypass or sample cell flow
meter tubes, investigate and correct immediately.
4.2.7 SCS pressure regulator
The OXY5500 analyzer is limited to a maximum 10 psig pressure. To ensure that this pressure is not exceeded, a
pressure regulator is provided inside the sample system. Refer to Appendix A →  for the correct pressure setting for
this regulator.
4.2.8 Measurement manifold controller
The measurement manifold controller is provided with the SCS. Typically a flow control needle valve and flow meter
similar to the sample bypass are used, but in some cases a differential flow controller is used. As with the bypass flow
control valve, if the flow control needle valve and flow meter must be used for sample shut-off, close the valve gently
and carefully to avoid damage.
4.2.9 Sample return/vent
Oxygen analyzers are inherently sensitive to sample pressure variations, so the analyzers must be calibrated to a
specific sample pressures. An optional pressure sensor is available to accommodate an SCS system with pressure
variations. Sometimes the analyzer is designed to vent the sample to atmosphere or an atmospheric pressure return
system. Return to a flare or other sample return must recognize the pressure limitations of the oxygen analyzer and
the calibration.
4.2.10 SCS heaters
Some analyzer systems have heated SCS enclosures for freeze protection. Refer to System Power Up →  for
instruction on heater use.
Heaters are considered accessories and not part of the overall analyzer certification.